storage battery maintenance and principles

7/27/2019 Storage Battery Maintenance and Principles

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FACILITIES INSTRUCTIONS,STANDARDS, AND TECHNIQUES

VOLUME 3-6

STORAGE BATTERYMAINTENANCE AND PRINCIPLES

Internet version of This Manual Created

June, 1998

HYDROELECTRIC RESEARCH AND

TECHNICAL SERVICES GROUP

The App earance of th e Internet Version of This

Manual May Dif fer from the Original but the Content does n ot

UNITED STATES DEPARTMENT OF THE INTERIORBUREAU OF RECLAMATION

DENVER, COLORADO


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TABLE OF CONTENTSSection Page

Flooded, wet cell, lead-acid battery maintenance schedule (last updated 12/31/97) . . . . . . . . . . . . . . . . 11 Condensed instructions: lead-acid batteries (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 Battery charging and specific gravity temperature correction . . . . . . . . . . . . . . . . . . . . 21.3 Voltage readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 Specific gravity readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 Temperature readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.6 Connection resistance readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.7 Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.8 Battery care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.9 Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.10 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.11 Battery troubles summarized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.12 Recommended actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.13 Cell replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Lead-acid battery principles (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.2 Full charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.3 Appearance of normal cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.4 Chemical changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5 Internal self-discharge and effect of impurities on floating voltage . . . . . . . . . . . . . . . 132.6 Temperature characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.7 Proper amount of charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.8 High-rate overcharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.9 Low-rate overcharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.10 Undercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.11 Over discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.12 Sedimentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.13 Replacement water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.14 Water replacement rate for lead-antimony cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.15 Water replacement rate for lead-calcium cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.16 Water replacement for lead-selenium cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.17 Adjusting specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.18 Hydrometer readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.19 Constant voltage charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.20 Battery life for different types and services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.21 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.22 Internal shorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.23 Normal sulfate and over sulfation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.24 Elimination of over sulfation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.25 Water treatment for over sulfation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Battery testing (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.1 Acceptance testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.2 Capacity tests to determine replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4 Optional instructions lead-calcium batteries (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . 224.1 Float charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.2 Initial charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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TABLE OF CONTENTSCCCONTINUED

Section Page

4.3 Voltage readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.4 Specific gravity readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.5 Heavy discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.6 Water replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Valve regulated lead-acid battery (gel cell) maintenance schedule (last updated12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5 Condensed instructionsvalve regulated lead-acid batteries (gel cells) (last updated12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.2 Float charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.3 Equalizing charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.4 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.5 Battery maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.6 Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.7 Voltage readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.8 Temperature readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.9 Connection resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.10 Internal resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285.11 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Vented nickel cadmium battery maintenance schedule (last updated 12/31/97) . . . . . . . . . . . . . . . . . . 316 Vented nickel cadmium battery principles (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.3 Chemical reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.4 Upon installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.5 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.6 Voltage readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.7 Temperature readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.8 Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.9 Battery discharge testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.10 Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366.11 Electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.12 Specific gravity readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.13 Electrolyte renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386.14 General care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.15 Battery records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396.16 Wall card records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7 Batteries for microwave and VHF radio equipment (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . 397.1 Lead-acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397.2 Nickel-cadmium batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8 Battery safety (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408.1 Explosive hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408.2 Electrolyte hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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8.3 Flame arresters purpose and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Section Page

8.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418.5 Battery rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448.6 Safety meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9 Battery charging equipment (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459.1 Motor-generator sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459.2 Static rectifier chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10 Replacement storage battery sizing (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4911 Standards (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

TABLES

Table

1 Flooded, wet cell, lead-acid battery maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Common voltage ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Valve regulated lead-acid battery maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 Vented nickel cadmium battery maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURES

Figure

1 Water consumption for lead-acid battery sizes and types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652 Placement of meter probes for connection resistance measurements . . . . . . . . . . . . . . . . . . . . . 73 Percent capacity of batteries with pasted and plante type plates for various

discharge rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674 Effect of concentration of electrolyte on cell capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695 Final voltage at various rates after charge is fully completed . . . . . . . . . . . . . . . . . . . . . . . . . . 716 Percent local action in 1.280 electrolyte versus specific gravity of electrolyte . . . . . . . . . . . . . . 737 Approximate variation of local action in lead-acid storage cells with changes in

specific gravity of electrolyte and changes in temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738 Approximate variation of capacity with temperature in lead-acid chloride-

accumulatortype storage cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759 Typical recharge curves at constant voltages following 100-percent discharges . . . . . . . . . . . . 77

10 Voltage probe placement for nickel-cadmium cells with different type connectors . . . . . . . . . 79

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TABLE OF CONTENTSCCCONTINUED

REPORT FORMS

Form Page

POM-133A Flooded lead-acid battery maintenance report (last updated 12/31/97) . . . . . . . . . . . . 51POM-133B Valve regulated lead-acid battery maintenance report (last updated

12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53POM-133C Nickel-cadmium battery maintenance report (last updated 12/31/97) . . . . . . . . . . . . . 55POM-134A Flooded lead acid batter connection resistance annual report

(last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57POM-134B Valve regulated lead-acid battery connection and internal resistance

annual report (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59POM-157 Lead-acid storage battery data (last updated 12/31/97) . . . . . . . . . . . . . . . . . . . . . 61POM-159 Nickel cadmium storage battery data (last updated 12/31/97) . . . . . . . . . . . . . . . . 63

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TABLE 1. - FLOODED, WET CELL, LEAD-ACID BATTERY

MAINTENANCE SCHEDULE

1

Maintenance New Battery Shift Monthly 3-Month Annual 5-Year

Visual Also See 1.10C &D FlameInspection ArrestersSee 1.7 See 8.3

Battery Float Panel Meter Battery Terminals Compare PanelVoltage Float Voltage with Digital Meter to DigitalSee 1.3 See 1.3A Voltmeter Voltmeter

Cell Float All Cells Pilot Cells All CellsVoltages with Digital with Digital with DigitalSee 1.3 Voltmeter Voltmeter Voltmeter

Specific Gravity All Cells Pilot Cells 10 Percent of All CellsReadings all CellsSee 1.4

Temperature Pilot Cells 10 Percent ofReadings All CellsSee 1.5

Connection All All ConnectionsResistance Connections

See 1.6

Battery Testing Acceptance Yearly Capacity CapacitySee 3.0 Test After Tests if 5-Year Discharge

1 week Test


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1. CONDENSED INSTRUCTIONS: LEAD-ACID BATTERIES

E1.1 PURPOS11. PURPOSE

The purpose of this section is to outline the duties and responsibilities forroutine operation and care of vented lead-acid batteries. Section 2 containsdetailed information on lead-acid battery principles.

1.21.2 BATTERY CHARGING AND SPECIF IC GRAVITY TEMPERATURE CORRECTIONBATTERY CHARGING AND SPECIFIC GRAVITY TEMPERATURE CORRECTION

A.A. Initial Freshening ChargeInitial Freshening Charge

To establish a reference, give each new battery, or reinstalled battery storedfor more than 3 months, an initial freshening charge. Use the equalizingvoltage given by the manufacturer for the type cell, but do not exceed themaximum voltage of other loads connected to the charger. Apply this chargeuntil each cell gasses freely and equally and specific gravity (sp.gr.) stops

rising. Just before the end of the initial charge, record the voltage of eachcell. About 20 minutes after the end of the charge, record the specificgravity of each cell, corrected to 77 EF. For every 3 EF above 77EF, add onepoint (0.001) to the reading. For every 3 EF below 77EF, subtract one point(0.001) from the reading. Use form POM-133A for these records and keepthem for the life of the battery.

ell.CPilot.1A.1 Pilot Cell.After the initial charge or to begin a yearly cycle, choose a pilotcell from one of the lowest specific gravity and lowest voltage cells. This cellis used as a representative for readings, for one year. Each year a new pilotcell is chosen.

eB. Float Charg.B Float Charge

Charge batteries continuously at the float voltage recommended by themanufacturer. Monthlyy take the voltage across the overall battery terminalswith an accurate digital meter and compare this reading with the chargerand bus voltmeters. If needed, adjust the charger float voltage based on thedigital meter. Adjust the charger and/or bus voltmeters to agree with thedigital meter if needed.

A battery is said to float when charging voltage is slightly greater than theopen circuit voltage of the battery. Floating current required to keep lead-

calcium cells at full charge is about one-fourth to one-third that of lead-antimony cells, but lead-calcium cells usually must be floated at a slightlyhigher voltage. Lead-selenium cells require float voltages slightly abovethose of lead-calcium.

The operation of a battery by float method is based on overall voltage appliedto the battery terminals. The voltmeter used must be very accurate. Aninaccurate meter can result in either over or undercharge and resultingproblems, which reduce life and service of the battery. See section 1.3.

Rev.12/31/97 2


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C.C. Equalizing ChargeEqualizing ChargeThe purpose of the equalizing charge is to ensure that every plate in everycell is brought with certainty to a state of full charge by a slight overcharge.

Do not perform equalizing charges on a routine basis. If one of the conditions belowoccurs, apply an equalizing charge at the voltage recommended by themanufacturer for the type of cell. Ensure that all cell levels are at the highlevel mark before beginning the charge.

1. Following heavy discharge.2. If specific gravity (corrected for temperature) of any cell is more than 10

points (0.010) below the full charge value while on float.

3. If the voltage of any cell is more than 0.04 volt below the average cellvoltage when the battery is on float.

4. If the level in any cell or cells falls at or near the minimum fill line a lotof distilled water must be added to restore the level to the maximum fillline. If this condition occurs, an equalizing charge must be performed torestore specific gravity.

5. If too little replacement water is being added, typically indicatingundercharging (see fig. 1 for typical water consumption).

Terminate the equalizing charge when all conditions below are met:

1. Every cell gasses freely and equally.2. The specific gravity of all low cells has stopped rising, determined by two

specific gravity readings measured over the last one-eighth of thecharging period.

3. The voltage difference between the highest and lowest cells is no greaterthan at the initial charge.

Failure to give equalizing charges when needed leads to problems. Theampere-hour capacity of weak cells greatly decreases. During discharge,these cells will be exhausted well ahead of good cells and then become over

discharged (see section 2.11) or over sulfated; the plates may buckle, andgrids may crack. Continued discharge may reverse the polarity, makingpositive plates out of the negatives and vice versa, which will destroy thecells.

If one section of the battery runs warmer than the rest, these cells have ahigher rate of internal self-discharge, and capacity gradually falls below theothers. Hence, a battery must be located so that sunshine or space heatersdo not affect a portion of the battery, which would mask internal self

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discharge temperature increases.

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D.D. Unattended StationsUnattended Stations

The equalizing charge may be terminated automatically by a timer. Use themanufacturers recommended charge time for the cell type. Set the timer toswitch off the equalizing charge and to reconnect the float charge. In theevent that the manufacturer does not provide a recommended charge time,3 days (72 hours) may be used as the charge time.

A "check charge" for batteries at unattended locations may be used to determine ifequalization is necessary. With a "check charge, the battery is placed oncharge at the equalizing rate. After allowing 15 or 20 minutes for the rate tostabilize, the voltages of individual cells are measured. If the highest andlowest cell voltages (while on charge at the equalizing rate) differ by nomore than 0.04 volt, the battery does not require equalizing. The batteryshould be equalized if the voltage differences exceed 0.04 volt. Use a digitalmeter accurate to 0.01 volt. The test described above is effective indetermining equality of cell charge. However, the test cannot be substituted

for a hydrometer in determining state of charge. All cells must be within 5F,the reason is described in paragraph 2.6, and the temperature must notbe below 55 F.

1.31.3. VOLTAGE READINGSVOLTAGE READINGS

Voltage readings should be taken in accordance with the followinginstruct ions. NNote: Accurate voltmeters are critical for extending battery life.Provide a digital voltmeter accurate to 0.01 volt reserved only for stationbattery duty and calibrate it or send it out for calibration at least once a year.

This voltmeter must be treated with extra care; do not use a shop meter orelectricians general-use meter for battery voltages.

A.A. Each Shift (Attended Stations) or DuringEach Shift (Attended Stations) or During Routine Inspections (Unattended Stations)Routine Inspections (Unattended Stations)

Check the voltmeter on the control panel to determine if the battery is beingcharged at the proper voltage. Adjust the battery charging voltage ifnecessary.

B.B. When Taps Are ChangedWhen Taps Are Changed

Check the voltage on the control panel when taps are changed on power orstation-service transformers. Adjust the battery charging voltage if

necessary.

C.C. During Equalizing ChargeDuring Equalizing Charge

Just before terminating the equalizing charge, measure the voltages of thehighest voltage cell and the lowest voltage cell of the battery to the nearest 0.01volt with an accurate digital voltmeter. The equalizing charge should becontinued if the voltage difference between the two cells is more than thatrecorded for the initial charge.

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D.D. MonthlyMonthly

With the charger in service, check the overall float voltage across the batteryterminals with an accurate digital meter and record on form POM-133A.

E.E. MonthlyMonthly

Check the pilot cell float voltage with an accurate digital voltmeter andrecord on form POM-133A.

F.F. QuarterlyQuarterly

Check the float voltage on all individual cells to the nearest 0.01 volt with anaccurate digital voltmeter. Take these readings as rapidly as possible andrecord them on form POM-133A. At the end of the yearly cycle, use thesereadings to determine the pilot cells for the next year.

1.41.4 SPECIFIC GRAVITY READINGSSPECIFIC GRAVITY READINGS

Specific gravity readings of vented lead-acid batteries must be taken inaccordance with the following instructions. Note: All specific gravity readingsmust be corrected to 77EF before recording (see 2.18). Do not attempt totake any specific gravity reading after adding water to a cell. The electrolytetakes several hours to mix after water is added.

A.A. MonthlyMonthly

Take the specific gravity reading of the pilot cell and record it on form POM133A.

B.B. QuarterlyQuarterly

Take specific gravity readings of 10 percent of the total number of cells andrecord them on form POM-133A. Rotate these cells so that readings aretaken on different cells each quarter.

C.C. AnnuallyAnnually

Take specific gravity readings of every cell and record them on form POM133A.

D.D. After Equalizing ChargeAfter Equalizing Charge

About 15 minutes after heavy gassing stops, take the specific gravity readingsof every cell and record them on form POM-133A. If two cells with thelowest specific gravity (checked over the last one-eighth of the chargingperiod) have not stopped rising, continue the equalizing charge.

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1.51.5 TEMPERATURE READINGSTEMPERATURE READINGS

All cells of a battery should be at the same ambient temperature. Heatsources such as sunlight, portable heaters, etc. must be blocked so they donot raise the temperature of individual cells. Record the room ambienttemperature before cell temperatures are taken.

Note: An accurate infrared (IR) camera may be used for temperatures;however, the camera calibration must be checked at least once each year. Ifpossible, take the annual temperature readings of the cells just after cameracalibration. I f the temperature spread of the cells exceeds 5 F (i.e., upperrows are warmer) the room ventilation may be inadequate.

A.A. MonthlyMonthly

Record the pilot cell temperatures on form POM-133A.


Record temperature readings of 10 percent of all the cells; rotate the subjectcells each quarter.


If an accurate IR camera is available, take the temperature of the batteryconnections during a load or discharge test, i.e., while current is flowing. Ifone or more of the connections are loose or dirty, their temperatures will behigher than the other connections.

1.61.6 CONNECTION RESISTANCE READINGSCONNECTION RESISTANCE READINGS

A.A. After InstallationAfter Installation

Using an accurate micro-ohm meter, record the resistance of eachconnection on form POM-134A. The readings should be on the order of afew micro-ohms (less than 100). Record the readings as a baseline on formPOM-134A. For additional information see IEEE 450-1995Maintenance,Testing , and Replacement of Vented Lead-acid Batteries, Annex D and F. See belowfor detailed instructions.

B.B. AnnuallyAnnually

Repeat resistance checks of the connections checked in step A above andcompare values. If any connection resistance has increased more than 20percent, clean, apply no-ox grease, retorque the connections, and retest.Fill out both as found and as left columns on form POM-134A.

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C.C. Recommended Method For Taking Annual Micro-Ohmmeter Readings Across BatteryRecommended Method For Taking Annual Micro-Ohmmeter Readings Across BatteryConnectionsConnections

Figure 2. - Placement of meter probes for connection resistance measurements.

Caution: Never place probes across a cell or cells (between positive andnegative posts), with the meter set on ohms. The meter may be destroyedand arcing may occur at the battery.

1. Make sure the battery is on float charge before beginning the readings.Obtain an accurate digital micro-ohmmeter, and set it to the lowest scale.

2. On cell No. 1 take the first reading between the connector lug and thefirst post (see fig. 2). This reading will be the resistance between thepost and connector lug and will be about one-half the middle readings.Record all readings on form POM-134A.

3. Take the second reading between opposite polarityposts (not connectors) ofcells No. 1 and No. 2. Following readings will be between positive andnegativeposts of adjacent cells. These middle readings will include theresistance of two connections (one on each post) and the intercelllead(see fig. 2). These readings will be about double the first and last.

4. Take the remaining middle readings as in step 4, proceeding from cell tocell.

5. Take the last reading between the last post on the last cell and theconnector lug as shown.

6. If high resistance is found, take readings from each post to its connectorto determine which of the two connections is bad. Mark this and allhigh-resistance connections for later repair.

7. After readings are complete, disconnect the charger and loads from thebattery. Caution: do not remove or make connections while current is flowing.Clean problem connections, retorque to manufacturers specifications,and apply no-ox grease. Retest the repaired connections and record theresistance in the as-left column on form POM-134A.

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1.71.7 VISUAL INSPECTIONSVISUAL INSPECTIONS

Visual inspections are made to assess the general condition of the battery,battery room, and safety equipment. See below and section 1.10 and recordon form 133-A.

A.A. MonthlyMonthly

Check for general cleanliness of the battery, mounting rack, and batteryroom. Check for electrolyte leaks and cracks in cells, and take correctiveaction if any are found. Check for corrosion at terminals, connectors, racks,and cabinets. Check the ambient temperature and make sure ventilationdevices (fans and vents) are operable. Check all the electrolyte levels andcorrect if necessary.

Check for availability and condition of all safety equipment, gloves, aprons,face shields, etc. (see section 8). Check for a full gallon of labeled

neutralizing solution, and operability of eyewash station or portable eyewashequipment. Check for operation and cleanliness of body wash station.Check for a class C fire extinguisher and check that it has been inspectedand tested according to schedule. Check for availability of insulated toolsand utensils so short circuits can be avoided. Check the hydrometer forcleanliness and cracking of rubber parts.

1.81.8 BATTERY CAREBATTERY CARE

A.A. Adjustment of Specific GravityAdjustment of Specific Gravity

Do not add or remove acid in any cell except when following instructions in

paragraph 2.17.

B.B. TemperatureTemperature

Never intentionally allow electrolyte temperature to exceed 100 EF.

C.C. CleanlinessCleanliness

Keep the battery room or cabinet clean and well ventilated. Keep cells,especially the tops, clean, dry, and free of electrolyte and corrosion residue.

D.D. Spilled ElectrolyteSpilled Electrolyte

At each battery room or cabinet, provide a labeled gallon jar of solutionconsisting of 1 pound baking soda to 1 gallon of water. Neutralize spilledelectrolyte with soda solution, rinse with water, and wipe dry. Do not allowany solution to enter the cells. Keep vent plugs tight and gas vents open.Any missing or worn vent plug gaskets should be replaced.

1.91.9 CHARGERSCHARGERS

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Chargers serve two important functions. The main function is to provide dc station power and to keep the battery charged. The second function is tobe able to replace the battery if the need arises. Two main types availableare silicon-controlled rectifier (SCR) and ferro-resonant. The two typesdiffer greatly. SCR chargers consist of a transformer with an SCR bridgeand filtering. All control and protection in these chargers is electronic.

These chargers are usually the cheapest type because the manufacturer canbuy SCRs and electronics off the shelf. Ferro-resonant chargers uses atransformer specifically designed for each application. When extremeconditions occur, these transformers saturate and limit, by design, themaximum current and voltage. Additional electronics are not needed. Thisfeature makes the chargers more durable and dependable in a power plantenvironment. The ferro-resonant type charger is therefore recommended.

Chargers normally are bought and operated in pairs to share the load. Bothchargers operating, with all safety features activated on both, will less likelyhave a double failure than if one is operating and one is in stand-by mode.

In an emergency, a charger on standby trying to power up and assume theduties of a failed charger may exceed its current or voltage limits beforesafety circuits are enabled. The result may be two failed chargers. The bestway to avoid this problem is to operate both chargers in parallel at all times,each supplying half the load.

The size of the chargers is very important to the life and service of thebattery. The chargers must have enough capacity to easily gas the batteryunder charging conditions. Chargers with too little capacity reduce batterylife. A smaller charger, though cheaper initially, can be the most expensiveon a long term basis.

A.A. Every ShiftEvery Shift

Check the panel voltmeter to see if the correct float voltage is being used forcharging.


Check each charger by turning off one, then the other, and see if eachcharger will carry the total load.


Check the accuracy of the charger panel voltmeter with the digital meter.

1.101.10 RECORDSRECORDS

Post a battery data card form POM-157 in a conspicuous location near thebattery, and keep accumulated forms in a permanent file.

Loss of capacity over time is shown by a gradual change in specific gravity of

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the cells. Keeping accurate records in the battery room is important.Comparison can be made easily between current and earlier readings. Acopy of forms POM-133A and POM-134A are included in the forms sectionand are available from Reclamations Technical Service Center in Denver.Four POM-133A quarterly reports and one POM-134A connectionresistance report are required for a 60-cell battery each year. Special care isnecessary to protect data sheets. Keep current records on clip boards or in alog book near the battery and transfer them to a permanent file at the end ofthe year.

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1.111.11 BATTERY TROUBLES SUMMARIZEDBATTERY TROUBLES SUMMARIZED

A.A. Lack of GassingLack of GassingLack of gassing while on charge may indicate an internal short betweenplates, i.e., the cell discharges internally as fast as it is being charged.

B.B. Specific Gravity or VoltageSpecific Gravity or Voltage

Specific gravity or voltage of a cell lower than other cells is an indication ofexcessive internal losses and may result from consistent undercharging.

C.C. ColorColor

Color or appearance of plates or sediment different from other cells isaddressed below:

1. Patches of white lead sulfate on either the positive or negative plates:caused by standing idle or undercharging for extended periods.2. Antimony deposit dark-slate patches on negative plates (usually near the

terminal): caused by charging at too high a rate or an aged cell nearingthe end of its service life.

3. Top layer of sediment white: caused by undercharging.4. Lumpy brown sediment: caused by overcharging.5. All white sediment no visible layers: caused by overcharging after

prolonged low float voltage.

6. Large flaking on the interplate collector bar: caused by being on floatcharge for extended periods at insufficient float voltage withoutequalizing charging being performed.

D.D. Plate ProblemsPlate ProblemsIf any checks below are excessive, capacity tests must be run to determine ifindividual cells or the entire battery should be replaced. See section 3.

1.

Cracks on the edges of the positive plate grids.

2. Light-colored sulfating spots on edges of plates below cracks mentionedin check No. 1 above.

3. Excessive sediment in the bottom of the case.4. Mossing or treeing on the tops of negative plates.

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E.E. WaterWater

1. Cell uses excessive water (check fig. 1 for typical water consumption):caused by excess charging rates, high operating temperatures, or leakingcell.

2. Cell requires very little water: caused by insufficient charging.FF. Buckling of PlatesBuckling of PlatesBuckling of positive plates indicates excessive sulfation caused byundercharging or excessive temperature. See sections 2.10, 2.22, and 2.23.

GG. Failure to Supply Rated Ampere-Hour LoadsFailure to Supply Rated Ampere-Hour LoadsFailure to supply rated ampere hours indicates discharged condition,excessive sulfation, or loss of active material from positive plates. Cells may

be worn out or active material may be gone from positive plates. See section3 for testing.

H.H. Surface Charge PhenomenonSurface Charge PhenomenonWhen a battery has been on float charge for a long time and is put underload with the chargers off, the voltage will drop rapidly. This drop is causedby plugging of some of the pores on the surface of the plates, which partiallyblocks the transfer of ions. The voltage may drop below the low-voltagealarm and trip settings. After this initial drop, the voltage will usuallyincrease to a level above the low-voltage alarm and trip settings. The batterywill then operate normally until its capacity is exhausted.

If the battery is exercised (partially discharged) on a routine basis, thevoltage dip can be reduced or eliminated. Turning off both chargers andallowing the battery to take the load for at least 15 minutes exercises thebattery. The first few times this procedure is performed, disconnect the lowvoltage trip relay to prevent an inadvertent trip. The first time the battery isexercised, the procedure should be performed several times in successionuntil the voltage drop stays above the alarm setting. Always give thechargers time to reduce charging current to float value before turning off thechargers again for the next cycle.

Each battery has its own characteristics, and the frequency of exercisingshould be adjusted so that the voltage drop does not cause the low voltagealarm. Start at a monthly cycle and experiment with increasing the timebetween exercises. The proper time between exercises exists when thevoltage drop is just above the alarm relay setting.

1.121.12 RECOMMENDED ACTIONSRECOMMENDED ACTIONS

If any cells seem to be in trouble, the whole battery should be given an

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equalizing charge, and then specific gravity readings should be taken on allcells. Ifall cells gas evenly and specific gravity ofevery cell is normal, all thebattery needed was the charge. Otherwise, all low gravities should berecorded, and an extra thorough charge, as described in section 1.2C shouldbe given. The temperature of all cells should be compared by thermometeror IR camera with the rest of the cells. Sulfated cells will run hot enough tocause damage if not corrected. Any cells that still will not gas with the extracharging should be investigated for impurities and inspected for internalshort circuits. See section 3 for testing.

Additional information may be obtained from IEEE Standard 450-1995Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries. If thisstandard does not help solve a problem, record the voltage of each cell andthe specific gravity of 10 percent of all the cells. Also, record the electrolytetemperature and the ambient temperature, then contact the batterymanufacturer for assistance.

1.131.13 CELL REPLACEMENTCELL REPLACEMENT

A faulty cell may be replaced by one in good condition of the same make,type, rating, and approximate age. A new cell should not be installed inseries with older cells except as a last resort. A battery may be operatedwithout several cells by proper adjustment of float and equalizing voltages,provided discharge capacity requirements can be met.

2. LEAD-ACID BATTERY PRINCIPLES

2.12.1 PURPOSEPURPOSE

This section describes the principles of lead-acid battery care and how todetermine if the care is adequate and correct. The most important part ofbattery care is a proper charging program. Keeping and comparing accuraterecords of physical conditions and measured data assists in determiningwhether the charging program is correct. Correct charging is critical forlong battery life and reliability of service.

The following discussion describes cell conditions with both proper andimproper operation and maintenance. These principles do not takeprecedence over the manufacturer's instructions, but provide explanationsand details.

2.22.2 FULL CHARGEFULL CHARGE

Knowing when a cell is fully charged is important. A cell is fully chargedwhen, charging at the equalizing rate, the cell is gassing, specific gravity hasstopped rising, and specific gravity remains constant for two successivereadings. Hydrometer readings must be corrected for any changes in celltemperature that have occurred between readings. These two readingsshould be taken during the last one-eighth of the charging period.

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2.32.3 APPEARANCE OF NORMAL CELLSAPPEARANCE OF NORMAL CELLS

Edges of positive plates do not give much information. Edges of negativeplates should be uniformly gray; they should be examined with a nonmetallic flashlight for sparkling from lead sulfate crystals. Correct floatcharging will cause no lead sulfate crystals. See section 1.10 for moreinformation on cell appearance.

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No visible change occurs when the cell is discharged a normal amount. Ifthe charging program is correct, sediment accumulates very slowly andshould never be white or lumpy. The charging program may requirechanges to produce a very scanty, fine, dark-brown sediment. The electrolyteshould be at the marked level, midway between top of the case and top ofthe plates.

2.42.4 CHEMICAL CHANGESCHEMICAL CHANGES

A fully charged cell has brown lead peroxide on positive plates and graysponge lead on negative plates.

On discharge, electric current converts active materials of positive andnegative plates to normal lead sulfate and uses up sulfuric acid tomanufacture lead sulfate. This process leaves the acid weak at the end ofthe discharge. Lead sulfate is white in color but cannot be seen on platesunless the cell is over-discharged, which produces over sulfation. This

condition makes the plates first lighter in color and finally mottled white inpatches or white all over.

Charging the cell reverses this process, converting lead sulfate in the platesto lead peroxide and sponge lead and producing sulfuric acid, which restoresthe specific gravity to normal. Chemical reactions in a storage cell are:

Battery Discharged Battery Charged

(+ plate) (- plate) (solutio (+ plate) (- plate) (solution)n

PbSO4 PbSO4 2H2O PbO2 + Pb 2H2 SO4+ + +

(lead sulfate) (lead sulfate) (water) (lead peroxide) (lead) (sulfuric acid)

As the charge nears completion little lead sulfate remains to convert to lead.The charging current begins to separate water into oxygen and hydrogen,which bubbles to the top of the electrolyte and forms a mixture of veryexplosive gases.

Quantity of ampere-hours available from a cell decreases with an increasing

rate of discharge. Available ampere-hours are much less at rapid rates ofdischarge (see fig. 3). The ampere hours also decrease for cells with weakerspecific gravity (see fig. 4).

2.52.5 INTERNAL SELF-DISCHARGE AND EFFECT OF IMPURIT IES ON FLOATINGINTERNAL SELF-DISCHARGE AND EFFECT OF IMPURITI ES ON FLOATINGVOLTAGEVOLTAGE

Lead-calcium and lead-selenium cells have the advantage of low internallosses, which remain constant for the life of the cell. Lead-selenium cells

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contain little antimony and do not have antimony migration like lead-antimony cells.

Fully charged lead-antimony cells discharge internally by an action betweenactive material and the grid. Impurities may hasten this action and mayresult in visible or invisible changes on the plates depending on the types ofimpurities present. No metals should be put into the electrolyte at any time, except acadmium test electrode. Impurities may prevent a proper floating voltage fromkeeping up the charge and may prevent an equalizing charge fromequalizing voltage, so a higher floating voltage may be required.

The rate of self-discharge is decreased by using a lower specific gravity. Therate increases as the cell temperature rises, as may be seen on the curves offigures 5 and 6. The charge will not be lost if a small charging current, justequal to the self-discharge rate, is given to the cell. This charge is known asa trickle charge and is usually made a little larger than necessary so as togradually restore losses caused by small loads connected to the battery.

Self-discharge increases with age to perhaps five times the initial rate. Thisprocess is believed to be caused by the antimony being deposited on thenegative plate in a form that behaves as an impurity. Many batteries usecalcium instead of antimony as the alloying material, which reduces theinternal discharge as indicated on figure 7.

2.62.6 TEMPERATURE CHARACTERISTICSTEMPERATURE CHARACTERISTICS

Operating temperature greatly affects performance of storage cells. Capacityis greatly reduced when cold, as shown by figure 8. The self-discharge rateis increased at warm temperatures, as shown by figure 7. The temperature

at which the electrolyte will freeze and burst cells is lowered as specificgravity rises. Little danger of freezing exists if the battery is kept wellcharged.

If charging current is kept constant, charging voltage will rise to a final valueand is one indication that full charge has been reached. This final voltageincreasesgreatly as the cell gets colder, as shown by figure 5. For this reason,do not try to terminate an equalizing charge by a relay that operates at aconstant voltage. This procedure would only work correctly for onetemperature. Relays are available where operating voltage varies withtemperature. This charge control must be subject to the same ambient

temperature as the battery.

If charging voltage is held constant, final charging current increases withtemperature, as also shown in figure 5. This condition is needed to offsetthe increasing internal self-discharge current. The constant voltage chargemethod automatically keeps the current at the value the battery needs forreplacing both the self discharge and load discharges.

2.72.7 PROPER AMOUNT OF CHARGEPROPER AMOUNT OF CHARGE

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If cells of either lead-antimony or lead-calcium are undercharged, service willbe poor and battery life short. Ifovercharged, service with either cell type willbe good, but excessive overcharging will shorten life. Proper charging,means slight overcharging to cause the least possible sedimentation and a minimum ofheavy gassing. This condition requires very little makeup water. Noperceptible sedimentation or buckling of plates occurs during charge at highor low rates if cells are not allowed to gas vigorously. Sedimentation startswith gassing and is proportional to the total amount of gas liberated. Lead-selenium cells do not have the grid growth or the lead-antimony cellproblems. Typical curves of recharge times after 100-percent discharge atthe 8-hour rate are shown in figure 9.

2.82.8 HIGH-RATE OVERCHARGINGHIGH-RATE OVERCHARGING

After a battery is fully charged, continuation of charging current at a highrate damages positive plates. Violent gassing takes place, bubbles form inthe interior of the active material, and the resulting pressure forces bubbles

through the porous active material. The active material restrains thebubbles sufficiently so that many particles of plate material are broken out.

These particles rise with the bubbles and result in a muddy red or browncolor of the electrolyte. Some of this fine sediment settles on negative plateswhere it short circuits. The sediment is converted to gray sponge lead andresults in a growth of moss-like sediment deposited on top edges of thenegative plates. This deposit indicates that high-rate overchargingpreviously occurred. The battery will overheat on sustained heavy chargerates. The temperature of the cells should never intentionally be allowed toexceed 100 F.

2.92.9 LOW-RATE OVERCHARGINGLOW-RATE OVERCHARGING

At lower rates of overcharge, bubbling is reduced and sediment falls to thebottom of the cell. Overcharging at a very slow rate disturbs electrolyte solittle that fine brown sediment falls in a vertical line, forming tiny ridges ontop of the sediment. Ridged sediment is a good indication that the recentovercharging was not at high rates. Obviously, overcharging should be keptat a minimum, and ridges should be small.

2.102.10 UNDERCHARGINGUNDERCHARGING

If the battery gets too little charging, unconverted sulfate remains on the

plates too long and hardens. The longer plates stay in less-than-full-chargecondition, the harder the sulfate becomes and the more difficult it is toreconvert. When new, the sulfate is easily converted back to soft activematerials by a normal charge, but a long overcharge is required to remove itafter becoming hard. Sulfate accumulates unnoticed, a little on eachcharge, if charging is not enough to eliminate all the sulfate. This residuebuild-up continues until a substantial portion of ampere-hour capacity islost. The remedy is to increase charging to give a slight overcharge. Thisprocedure must be put into practice while the battery is new and followed

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for the life of the battery (see also paragraph 1.2CEqualizing Charge).Prolonged undercharging also leads to large flaking on the interplatecollector bar.

Sulfate build-up caused by undercharging is the most common cause of buckling plates andcracked grids. Sulfate takes up more room than the original material and strains the plates outof shape. The pressure of expanding active material can break separators andcause short circuits.

A badly sulfated cell should be treated as described in section 2.24. Ifcharged at too low a rate, the hardened sulfate is thrown out of plates andsettles in white ridges on the cell bottom. At higher rates, the gassingdistributes the sediment evenly without ridges. An over sulfated cell hashigh internal resistance and requires extra voltage across the cell, whichalso causes them to develop higher temperatures on charge. Buckled orcracked plates cannot be repaired by removal of sulfate but may be used aslong as they retain satisfactory ampere-hour capacity. See section 3 for

capacity testing.

2.112.11 OVER DISCHARGEOVER DISCHARGE

The plates suffer greatly when over discharged. Voltage per cell should not beallowed to drop below 1.75 volts. Specific gravity should not be allowed todecrease below the limit given by the manufacturer, which is different forvarious types and sizes of cells. Asnormal discharge proceeds, activematerials are converted to normal lead sulfate, which requires only slightlymore space than active materials. Over discharge forms more lead sulfate inthe pores of the active material than they are able to hold. This process mayexpand and bend or buckle plates or crack grids. In some instances,

sufficient pressure is created to crack or puncture separators.

2.122.12 SEDIMENTATIONSEDIMENTATION

The history of each cell is shown by the sedimentation because successivelayers are laid down in colored strata.. These layers can be seen edgewiseagainst the inside of the case. Layers of fine, dark gray show periods ofexcessive charging (current too high or charge too long). Lumpy gray layersindicate times the battery was over discharged. These layers are generallycovered by a layer of white sulfate from the following charge. A considerableamount of sediment and slivers will be found initially in Gould processed

plate batteries. This condition is a normal result of the forming process.Some additional sediment and slivers will be dislodged in shipment and willaccumulate at the bottom of the case of these batteries during the first fewequalizing charges. With this exception, a perfectly charged battery shouldhave nothing but fine brown sediment, free from lumps and as scanty aspossible. If some experimenting is done with the charging program, slightundercharging may result in a white sulfate layer. This layer indicates thatthe charging should be slightly increased.

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2.132.13 REPLACEMENT WATERREPLACEMENT WATER

As batteries are charged, a small quantity of water in the electrolyte isbroken down into hydrogen and oxygen by the charging current. The gasesare dissipated through openings in vent plugs. As this process takes place,electrolyte level gradually lowers until distilled water must be added.Commercially available "demineralized" water has been found by test to beequal or superior to commercial or "in plant" distilled water. Referencesthroughout this bulletin to "distilled water" do not preclude the use of"demineralized water. Do not add water in excess of the maximum levelmark. Never store distilled water in a metallic container. Use glass, plastic,or rubber containers.

Water consumption of batteries is indicated on figure 1. Take an average ofthe amount of water added over several months and compare with theamounts given on figure 1.

2.142.14 WATER REPLACEMENT RATE FORWATER REPLACEMENT RATE FOR LEAD-ANTIMONY CELLSLEAD-ANTIMONY CELLS

Lead-antimony cells begin their lives with low water consumption, whichincreases as much as five times toward the end of their lives (see fig. 1).Capped cells evaporate very little water, and loss is caused by gassing and isproportional to the amount of charge the battery receives. Heavy gassingrequires frequent additions of distilled water. The water should be added

just before or at the beginning of a charge so that gassing will ensurethorough mixing before specific gravity readings are taken. Proper chargingminimizes distilled water replacement by limiting the amount of gasgenerated to a small quantity. This method is much easier thanovercharging and having to refill cells frequently. It also extends the life of

the battery.

2.152.15 WATER REPLACEMENT RATE FORWATER REPLACEMENT RATE FOR LEAD-CALCIUM CELLSLEAD-CALCIUM CELLS

Frequent additions of distilled water in small amounts are not desirable.Water additions two or three times a year will probably be sufficient at mostinstallations. The electrolyte in all cells should be maintained within 1/4inch below the high level mark. Calcium cells, because of greater purity oftheir components, require only about one tenth the water needed byequivalent size antimony cells. This low requirement remains constantduring the entire battery life. See figure 1 for water consumption rate.

2.162.16 WATER REPLACEMENT FOR LEAD-SELENIUM CELLSWATER REPLACEMENT FOR LEAD-SELENIUM CELLS

Water replacement should only be necessary every 12 to 18 months if thebattery is not subjected to many discharges. If several discharges areexperienced, water replacement should be performed as with the lead-calcium cells in paragraph 2.15 above. Water consumption is lowthroughout the life of these cells.

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2.172.17 ADJUSTING SPECIFIC GRAVITYADJUSTING SPECIFIC GRAVITY

Specific gravity shouldnevernever be adjusted until the gravity is definitelyestablished to be wrong. Before adjusting for low gravity, make sure that thegravity cannot be raised by equalizing (see 1.2 C). Continue the chargeuntil the specific gravity shows no rise, and then charge for 3 more hours.Hydrometer readings must be taken as indicated in 2.18 below. Never make agravity adjustment on a cell that does not gas on charge. Remove some electrolytefrom the cell and replace it with pure, 1.300-gravity sulfuric acid, whichconsists of 30-percent concentrated acid and 70-percent distilled water byvolume. Recharge until all cells gas for an hour. Repeat the procedure ifthe gravity is still not normal. To lowerthe gravity, replace some of theelectrolyte with distilled water.

2.182.18 HYDROMETER READINGSHYDROMETER READINGS

Provide two hydrometers of high accuracy and sensitivity and check them

against each other frequently. The hydrometers should be replaced every 2to 3 years. The hydrometer must be held vertically for accurate specificgravity readings. Do not take readings after adding water (or acid) until theelectrolyte has had time to mix thoroughly (not less than 1 hour whengassing or 2 days if not gassing for antimony cells, and several weeks forcalcium cells in floating service). Use a long nozzle syringe and takesamples several inches down to minimize errors. Bubbles in the electrolytecause errors, and readings should not be taken sooner than 15 minutes aftergassing has stopped.

Specific gravity of electrolyte must be corrected for temperature. Subtractone point (0.001) from the specific gravity reading for each 3 EF the

temperature is below 77 F, and add one point (0.001) for each 3 EF thetemperature is above 77 F. The recommended specific gravity spreadbetween all cells is 0.010.

2.192.19 CONSTANT VOLTAGE CHARGINGCONSTANT VOLTAGE CHARGING

Constant voltage charging is the preferred method because of extendedservice life. If charging equipment is suitable for a continuously floatingcharge at a constant voltage, the proper floating voltage should be chosenfrom the manufacturers data. If the voltage is given for a single cell,multiply this voltage by the number of cells in the battery.

2.202.20 BATTERY LI FE FOR DIFFERENTBATTERY LIFE FOR DIFFERENT TYPES AND SERVICESTYPES AND SERVICES

The life of various types of cells can vary markedly. Valve regulated lead-acid cells have the shortest life. Formed plates of the Plante or Manchextype on light duty and floating charge have a longer life, usually 14 to 18years. Pasted plate Plante cells may be expected to last in excess of 25 yearson float charge. Formed plate cells, if cycle charged, usually last only about9 years. Lead-calcium cells on constant float charge typically last 12 to 15

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years. Lead-selenium cells have a longer life expectation than lead-calciumor lead-antimony. A battery is considered worn out when it fails to deliver80 percent of its original capacity.

2.212.21 CLEANLINESSCLEANLINESS

Battery connections must be clean, bright, and free of corrosion for thebattery to perform. Corrosion that is not cleaned off terminals periodicallywill spread into areas between posts and connectors. This condition willdevelop into a high resistance connection and cause heating and wastedcapacity. The battery and surrounding parts should be kept clean, dry, andfree of acid. Sulfuric acid absorbs moisture, and spilled electrolyte will notdry up. If electrolyte is spilled or sprayed out of the cells on charge,neutralize with a solution of baking soda (1 pound of soda to 1 gallon ofwater), then rinse with distilled water and dry with a soft cloth. A labeled jarof soda solution at least one gallon, must be kept in the battery room. Care should betaken to prevent the solution from getting into the cells. Make sure vent

plugs are open, flame arresters and dust caps are in place, and allcomponents are in good condition.

2.222.22 INTERNAL SHORTSINTERNAL SHORTS

A short circuit through a separator may be caused by:

1. Insufficient charging causes material in the plates to become mostly leadsulfate. The lead sulfate expands and, if the grid does not crack to relievethe strain, the plate will become distorted. This condition is commonlyknown as buckling. The buckling is most pronounced at the four cornersof the positive plates, where shorts are most likely to occur.

2. Impurities in the solution caused by using contaminated water or dirtyutensils.

3. Excessive overcharging causes the grid specific gravity to be partiallyconverted to lead peroxide, which reduces mechanical strength andallows positive and negative plate contact.

A short in a cell can be detected by falling specific gravity and falling cellvoltage. In some cases, an orange discoloration occurs at the point of theshort. If a short is long standing, disintegration of the positive plate will

occur at the point of contact with the negative because of the conversion ofpositive plate material to negative.

2.232.23 NORMAL SULFATE AND OVER SULFATIONNORMAL SULFATE AND OVER SULFATION

During discharge of a battery, "normal" sulfate is formed, which is requiredto produce current. If charging is neglected, the sulfate fills the pores of theplates and makes the active material dense and hard. This condition isreferred to as "over sulfated."

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Normal lead sulfate formed on discharge is in a form that a charge willeasily reconvert. When a battery is "over sulfated," plates are less porousthan normal and absorb a charge with difficulty. With this condition, anordinary charge will not reconvert all the sulfate to sulfuric acid and specificgravity remains below normal. Active material of "over sulfated" negativeplates is light in color and either hard and dense or granular and gritty andeasily disintegrated. The negative plates require the prolonged chargenecessary to restore an "over sulfated" battery. An individual cell maybecome "over sulfated" by external grounding, by an internal short, or bydrying out because of failure to add water. Over sulfation may also be causedby prolonged low float charging.

2.242.24 ELIMINATION OF OVER SULFATIONELIMINATION OF OVER SULFATION

A battery or cell that is "over sulfated" should be charged fully in the regularway until specific gravity stops rising. Then one of the weakest cells shouldbe discharged through a load resistor at the normal 8-hour discharge rate to

a final voltage of 1.75 volts. The battery is not over sulfated if therepresentative cell gives normal capacity, that is, about 100 percent ratedcapacity for a fairly new battery or down to 80 percent of initial ratedcapacity for a battery nearing the end of its expected life.

If the above capacity is not obtained, possible over sulfation should betreated as follows:

1. In cases where one or more individual cells have become "over sulfated"and the rest of the battery is in good condition, these cells should betreated separately after removing them from the circuit.

2. Recharge the removed cells at half the 8-hour discharge rate. Recordhydrometer readings and temperature at regular intervals (3 to 5 hours)during the charge to determine if rising specific gravity has peaked.Maintain constant electrolyte level by adding water after each reading.Do not add water before taking readings.

3. Continue the charge, recording the readings until no further specificgravity rise has occurred in any cell for 10 hours. If the temperaturereaches 100 F, reduce the current or temporarily interrupt the charge soas not to exceed this temperature. When the specific gravity has reachedmaximum, terminate the charge and record the hydrometer reading of

each cell.

4. The cells must be replaced if they again fail the capacity check in 2.24.

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2.252.25 WATER TREATMENT FOR OVER SULFATIONWATER TREATMENT FOR OVER SULFATION

In cases of emergency such as plant power loss or loss of both chargers, along discharge to the point of over-discharge may make the battery difficultto recover. Over sulfation may have occurred such that prolonged chargingset forth in section 2.24 may not recover the battery.

The water treatment should only be attempted in an emergency as a lastlastresort after prolonged charges will not restore the specific gravity.

The principle is to reduce the specific gravity in steps by removing a portionof the electrolyte and replacing it with distilled water, then charging thebattery after each step. As the specific gravity is reduced and the charge isapplied, the sulfate is dissolved from the plates by lower specific gravityelectrolyte at each step. The electrolyte becomes more and more like purewater, making it easier for the sulfate to transfer off the plates into theelectrolyte. Once the sulphates have been dissolved and removed, the

process is reversed to bring the electrolyte back to normal specific gravity.

The steps are as follows:

1. Reduce the specific gravity to about 1.050 to 1.100 by removing some ofthe electrolyte and replacing it with distilled water.

2. Charge the battery at the equalizing rate until the specific gravity of thepilot cell stops rising for two consecutive readings. However, do notcharge longer than 48 hours before the next step.

3. Again reduce the specific gravity as in step 1 above and repeat the chargein step 2.

4. Repeat the above steps until the maximum specific gravity obtained at theend of a charge is less than 1.150.

5. Reverse the above process by removing some of the weakened electrolyteand replacing it with 1.300 specific gravity acid. The amount to bereplaced is about the same as that in step 1 above. Do not try to speed upthe process by replacing more of electrolyte than that removed in steps 1through 4.

6.

Charge the battery as in step 2 above, checking the specific gravity of 10percent of the cells.

7. Repeat steps 5 and 6, increasing the specific gravity until it is just belownormal operating value. Record the specific gravity of all the cells on thelast step.

8. Place the battery back under normal float charge and service.

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9. After 1 month under normal service, the battery should be given acapacity test to see if the battery must be replaced (see section 3.2).

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3. BATTERY TESTING

The purpose of this section is to describe recommended testing proceduresand intervals. Information herein consists of guidelines only and is notintended to replace manufacturers recommendations. Followmanufacturers information if a conflict between these guidelines andmanufacturers information is encountered.

3.13.1 ACCEPTANCE TESTINGACCEPTANCE TESTING

Acceptance testing should be performed no sooner than 1 week after thebattery has had its initial freshening charge (see section 1.2 A). This testmay be done at the factory before shipping if specified. This test should beat least a 3-hour discharge test and should provide at least 90 percent ofrated capacity. An 8-hour discharge test for acceptance is preferred, and 90percent of rated capacity should be required.

3.23.2 CAPACITY TESTS TO DETERMINE REPLACEMENTCAPACITY TESTS TO DETERMINE REPLACEMENT

To establish whether a battery is nearing the end of its useful life, load testthe entire battery as outlined below at 5-year intervals. This test should berepeated annually if the capacity has dropped below 90 percent.

A.A. After the battery has been fully charged by equalizing, return it to floatservice for at least 72 hours, but less than 30 days before performing thetest.

B.B. Check all battery connections with a micro-ohmmeter to ensureconnections are clean and low resistance. An IR camera may be used

just after the discharge test has begun to check the connections.Temperature will be higher on poor connections. If poor connections arefound, stop the test and repair the connections before continuing.

C.C. Record the specific gravity and voltage of each cell just prior to the test.D.D. Record the temperature of the electrolyte of 10 percent or more of the

cells (an IR camera may be used and the temperature of cell cases maybe recorded) to establish an average temperature.

E. Record the battery terminal float voltage. Use an accurate digitalvoltmeter.

F.F. Take precautions to ensure that a battery failure will not jeopardize otherequipment. Discharge the battery through a suitable resistor and anammeter for 3 hours at rated 3-hour discharge current. Leave thecharger in normal float operation and record each cell voltage every half-hour during discharge. Watch closely during the last hour and time theexact end point accurately. After ambient temperature correction to77F, if the minimum voltage of 1.75 in any cell is reached before 3 hours

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has elapsed, the test should be stopped and the ampere-hours dischargeshould be computed. Capacity can be determined by referring to figure3. Testing should be done each year if the capacity is less than 90percent of the original rating. The entire battery should be replaced assoon as possible after capacity drops below 80 percent of original. Thebattery cannot be relied upon in an emergency if it has deterioratedbelow 80-percent capacity.

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4. OPTIONAL INSTRUCTIONS LEAD-CALCIUM BATTERIES

4.14.1 FLOAT CHARGEFLOAT CHARGE

For a typical, 60-cell, lead-calcium battery floated at 2.17 volts per cell andequalized at 2.33 volts per cell, the normal voltage range would be 130.2 to139.8 volts. At many locations, the higher voltage cannot be tolerated forthe 6 or more days required for equalizing, particularly where the battery isa source of power for electronic equipment. Lead-calcium batteriesdo notrequire equalizing if floated between 2.2 and 2.25 volts per cell. This voltagewould give a 60-cell battery a voltage between 132 and 135 volts. Lead-calcium batteries have a distinct advantage when constant voltage isdesirable. To match the battery voltage to the rated voltage of theequipment served, the number of cells should be selected to provideoptimum voltage when floated to eliminate the equalizing charge. Thisprocedure should be considered when replacing batteries. The table belowlists some common voltage ranges.

Table 2. - Common voltage ranges.

Numb Voltage Rangeer (volts)ofCells

12 26.4 to 27.023* 50.6 to 51.7524 52.8 to 54.0

58* 127.6 to 130.559* 129.8 to 132.75

60 132.0 to 135.0116* 225.2 to 261.0120 264.0 to 270.0

* The low battery alarm must be calibrated to reflect the lower number of cells.

4.24.2 INITIAL CHARGEINIT IAL CHARGE

An initial charge is not required because the battery will charge properly atthe above voltages. After about 2 weeks, initial cell voltages and specificgravity readings should be recorded on form POM-133A. Increase thevoltage to 2.33 to 2.38 volts per cell (connected equipment permitting) if theinitial charge must be completed sooner.

4.34.3 VOLTAGE READINGSVOLTAGE READINGS

A.A. Each Shift (Attended Stations) or During Routine Inspections (Unattended Stations)Each Shift (Attended Stations) or During Routine Inspections (Unattended Stations)

Check the charger panel voltmeter to determine if the battery is being

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floated at the proper voltage. Adjust the battery charging voltage whennecessary, and check when the power or station-service transformer taps arechanged.

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B.B. MonthlyMonthly

Check voltage across the battery terminals with an accurate digital voltmeterand adjust the panel voltmeter if necessary. Record pilot cell voltages to thenearest 0.01 volt, measured with an accurate digital voltmeter, on formPOM-133A. Battery is functioning normally if all cells are above 2.14 volts.

C.C. QuarterlyQuarterly

Check voltages across all individual cells and record them on POM-133A.

4.44.4 SPECIFIC GRAVITY READINGSSPECIFIC GRAVITY READINGS

A.A. Monthly (Attended Stations) or During Routine Inspections(Unattended Stations)Monthly (Attended Stations) or During Routine Inspections(Unattended Stations)

Read the specific gravity of the pilot cell. For accurate readings, hold thehydrometer vertically and use a long nozzle syringe about one-third down

from the top. Record the pilot cell specific gravity, corrected fortemperature, on form POM-133A.


Read the specific gravity of 10 percent all cells and record, corrected fortemperature, on form POM-133A.


Read the specific gravity of 100 percent of the cells, corrected fortemperature, and record on form POM-133A.

4.54.5 HEAVY DISCHARGEHEAVY DISCHARGE

The battery should be recharged as quickly as possible following a heavydischarge. This recharge can be done by raising the charging voltage to themaximum allowed by other circuit components but not greater than therange of 2.33 to 2.38 volts per cell. The battery should be returned tonormal voltage after the capacity been restored.

4.64.6 WATER REPLACEMENTWATER REPLACEMENT

Add water only when the water level approaches the low level mark or priorto an equalizing charge. This step should be needed every 2 or 3 years witha proper charging program.

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TABLE 3. - VALVE REGULATED LEAD-ACID BATTERY (GEL CELL)

MAINTENANCE SCHEDULE

31

Maintenance New Battery Shift Monthly 3-Month 6-Month Annual

Visual GeneralInspection InspectionSee 5.6

Battery Float Panel Meter Battery Float VoltageVoltage Float with Digital VoltmeterSee 5.7 Voltage

Cell Float All Cells Pilot Cells All CellsVoltage with Digital with Digital with DigitalSee 5.7 Voltmeter Voltmeter Voltmeter

Temperature All AllReadings Cells CellsSee 5.8

Connection All 25 Percent AllResistance Connections of All ConnectionsSee 5.9 Connections

Internal All All

Resistance Cells CellsSee 5.10

Battery Acceptance Capacity Test 6Testing Capacity months if 1-yearSee 5.11 Testing test


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5. CONDENSED INSTRUCTIONSCC

VALVE REGULATED LEAD-ACID BATTERIES (GEL CELLS)

5.15.1 GENERALGENERAL

Valve regulated lead-acid batteries (VRLA) are usually manufactured inmulti-cell blocks, (called modules) rather than single cells. The cases areoften made of ABS plastic material and do not permit visual inspection ofplates or electrolyte levels. They are called starved electrolyte or absorbedelectrolyte cells and operate under a positive pressure. The hydrogen andoxygen are not expelled but recombined. Cells are sealed and require nowater addition or specific gravity readings. These cells are typically leadcalcium pasted-plate type cells with the electrolyte retained in gel orfiberglass mats.

These batteries are normally used for emergency lighting,telecommunications, and other uninterrupted power supply (UPS) service.

They are best applied where long slow discharges are needed. Heavy shortdischarges required for breaker operations are not recommended for thistype battery. The life has been found to be only 18 months to 10 years inactual service.

These cells are not flooded and do not effectively dissipate heat. Thischaracteristic can lead to thermal runaway if ambient and batterytemperatures are not carefully controlled (see 5.2 below). Cases haveoccurred in which the battery has burst into flame. Maintaining the cells asclose as possible to 77 EF is imperative. Ambient temperature should bemaintained as close as possible to 72 EF. Air circulation must be sufficientto eliminate any ambient temperature differences. The maximum celltemperature spread (hottest to coldest cell) should not exceed 5 EF, and thehottest cell should not be more than 5EF above ambient. Coldertemperatures reduce capacity, and higher temperatures greatly reduce service life.About 50 percent of the service life will be lost for every 15 EF above 77EF.Do not allow sunlight or other heat sources to raise the temperature ofindividual cells. These cells are not recommended for station service because of thesecharacteristicscharacteristics.

VRLA modules/cells are typically shipped fully charged and do not requireinitial charge.

5.25.2 FLOAT CHARGEFLOAT CHARGE

VRLA cells are typically floated at 2.25 to 2.30 volts depending on themanufacturer. Correct battery float voltage is critical for valve-regulatedcells. The float voltage must be within the manufacturers recommendedlimits compensated for temperature. See the manufacturers literature fortemperature compensation of float voltages.

When VRLA cells are operated on float at normal full charge, no net

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chemical reaction occurs and almost all the overcharge energy results inheat generation. If the environment is such that the heat produced can bedissipated, no thermal runaway problem occurs. If the rate of heatgenerated exceeds the dissipated rate, the battery temperature rises andmore current is required to maintain the float voltage. The additionalcurrent results in more heat generation, which raises the batterytemperature further, and the cycle is repeated. Thermal runaway anddestruction of the battery result. Elevated ambient temperature (above 72F)or cell and/or charger malfunction will aggravate this condition.Ventilation and temperature control is critical for VRLA cells, and thebattery should reach thermal equilibrium at no more than 5F aboveambient for the hottest cell.

As cells approach full charge, battery voltage rises to approach the chargeroutput voltage, and charging current decreases. The battery is fully chargedwhen the charging current has not changed more than 10 percent for morethan 3 hours. If the charging voltage has been set higher than float voltage

to reduce the charging time, reduce the charging voltage to normal floatvalue after the charging current has stabilized. Caution: Never exceed themaximum charging voltage recommended by the manufacturer.

5.35.3 EQUALIZING CHARGEEQUALIZING CHARGE

Equalizing charge is not normally performed on VRLA cells. An equalizingcharge may be necessary if a low float voltage is indicated or if a fastrecharge is needed. The battery manufacturer should be consulted beforeproceeding if an equalizing charge is needed. The exact voltages and chargetimes indicated by the manufacturer must be followed carefully.

5.45.4 CHARGERCHARGER

A VRLA cell charger must have at least two capabilities: (1) extra electricalfiltering to protect the cells from AC ripple, which may lead to thermal runaway, and (2) temperature compensation to prevent thermal run-away. Donot try to charge these cells with a charger designed for afloodedlead-acidcells.

5.55.5 BATTERY MAINTENANCEBATTERY MAINTENANCE

The regimen described below is strongly recommended to maximize

performance and life expectancy. See manufacturers data and IEEE 1188-1996Recommended Practice for Maintenance, Testing, and Replacement of Valve-RegulatedLead-Acid (VRLA) Batteries for Stationary Application for further information.

5.65.6 VISUAL INSPECTIONSVISUAL INSPECTIONS

Visual inspections are made to assess the general condition of the battery,mounting rack and battery room, and safety equipment.

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A.A. MonthlyMonthly

Check for general cleanliness of the battery, mounting rack, and batteryroom. Check for electrolyte leaks and cover integrity, and take correctiveaction if needed. Check for corrosion at terminals, connectors, racks, andcabinets. Check the ambient temperature and make sure all ventilationequipment (fans, vents, etc.) is operable.

Check for availability and condition of all safety equipment, gloves, aprons,face shields, etc. Check for a full gallon of labeled neutralizing solution.Check for cleanliness and operability of eyewash station or portable eyewashequipment and body wash station (see section 8.2). Check for a class C fireextinguisher and ensure that it has been inspected and tested according toschedule. Carbon dioxide (CO2) fire extinguishers are not recommendedbecause of the cooling effect they will have on the battery. Check foravailability of insulated tools and utensils so short circuits can be avoided.

5.75.7 VOLTAGE READINGSVOLTAGE READINGS

An accurate digital voltmeter is critical for extended life of the battery (seesection 1.3). At a constant float voltage, the charging current will increaseas the temperature of the electrolyte increases. Therefore, cells of highertemperature will indicate a lower cell voltage. See figure 10 for propermeter probe placement. Place the probes across the posts of the cell so asnot to include the voltage drops across the intercell connections.

A.A. I nitial VoltageInitial Voltage

Readings of all cells should be taken and recorded about 24 hours after

placing the battery in float. Select the cell/module with the lowest floatvoltage as the pilot cell for future readings. Use form POM-133B for allvoltage readings.

B.B. Each ShiftEach Shift

Check the voltmeter on the charger and adjust the float voltage if necessary.

C.C. When Taps Are ChangedWhen Taps Are Changed

When taps are changed on the power or station service transformers, check

the float voltage on the charger panel and adjust if necessary.

D.D. MonthlyMonthly

Check and record the voltage of the pilot cell with an accurate digitalvoltmeter.

E.E. MonthlyMonthly

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Check and record the float voltage across the whole battery with an accuratedigital voltmeter. Compare this reading to the panel voltmeter and adjustthe panel meter to agree with the digital meter if necessary.

F.F. Every Six MonthsEvery Six Months

Check and record the voltage of each individual cell with an accurate digitalvoltmeter.

5.85.8 TEMPERATURE READINGSTEMPERATURE READINGS


After 24 hours on float and the temperatures have stabilized, recordtemperatures of each individual cell on form POM-133B. Use an accuratesurface thermometer and take the readings on the negative posts. Accuratereadings are critical for extended life and performance. Check the

thermometer for accuracy at least once per year. Take all temperaturereadings only on float. Do not try to take post temperatures while thebattery is discharging. The resistance of the connections causes errors intemperature readings. An accurate IR camera may also be used fortemperature readings.


Take temperature readings of each individual cell and record them on formPOM-133B. Compare readings with the initial and all prior temperaturesfor trending purposes. The highest temperature cell will typically also havethe lowest voltage.

5.95.9 CONNECTION RESISTANCECONNECTION RESISTANCE

See section 1.6C for detailed instructions.


Record resistance of each connection between the cell post and theinterconnection strap on form POM-134B. Contact the manufacturer forexpected readings for specific cells. See figure 2 in section 1.6C or figure 10at the back of this FIST for resistance probe placement. Clean, retorque,

and re-coat with no-oxide grease any connection with a resistance 20percent or more above the manufacturers recommended value. Use thesevalues as a baseline. Caution: Neverput meter leads acrossa cell with thefunction switch on ohms. This procedure will place a voltage across themeter instead of a resistance.


Record the resistance of 25 percent of the connections as in step A above

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and compare them with the previous readings. Rotate the measuredconnections each quarter. Repair those that have increased 20 percent inresistance.

C.C. AnnuallyAnnuallyRecord the resistance of all the connections as in step A above and comparethem with the previous readings. Repair those that have increased 20percent in resistance.

D.D. During

storage battery maintenance and principles

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